Gravity Actuated Flow Control Apparatus and Method

ABSTRACT

Embodiments of a flow control apparatus of the present invention generally include a vessel equipped with a substantially vertical, bottom-feeding liquid inlet line, a vapor space pressure equalization line, and a liquid outlet, wherein the vessel contains a pair of connected, horizontally oriented, O-ring and/or piston ring equipped sealing plates that are designed to rise and fall as a pair in response to gravity provided liquid pressure in the sump of the vessel, whereby an elevation of the sealing plates provides the liquid in fluid communication with the liquid outlet via internal orifices fluidly connected to one or more fluid conduits. Embodiments of a method of using embodiments of an apparatus of the present invention to control liquid flow are also provided.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/882,741, filed on Aug. 5, 2019, which application is incorporatedherein by reference as if reproduced in full below.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable.

FIELD OF THE INVENTION

The present invention generally relates to sulfur processing. Moreparticularly, embodiments of the present invention are directed to anapparatus and method for controlling the flow of molten sulfur in anindustrial application.

BACKGROUND OF THE INVENTION

In many applications, controlled flow of a liquid, such as moltensulfur, is accomplished by utilizing a device, whereby liquid isintroduced to an apparatus such that the liquid contacts a moveableboundary component that is directionally biased (e.g., downward) suchthat the boundary component prevents flow of the liquid until the liquidpressure exceeds the biasing force, whereupon the boundary component isdisplaced (e.g., upward) and the liquid is allowed to flow through afluid outlet. In such a system, once the liquid pressure diminishes to alevel less than the biasing force, the boundary component is replaced inits original position (i.e., “reseals”), and liquid flow through thefluid outlet is prevented. Historically, the biasing force was providedby a spring or the like, which is prone to wear and degradation overtime. Some recent apparatuses utilize a pressurized fluid to provide thebiasing force. Examples of such technology are disclosed in U.S. Pat.No. 9,752,696, issued Sep. 5, 2017, and U.S. Pat. No. 10,054,236, issuedAug. 21, 2018, both to the present inventor, which are both incorporatedherein by reference in their entirety. While such technology is useful,in certain systems it would be useful to provide the required biasingforce without the necessity of providing and maintaining a pressurizedfluid.

BRIEF SUMMARY OF THE INVENTION

Embodiments of an apparatus of the present invention generally include avessel equipped with a substantially vertical, bottom-feeding liquidinlet line, a vapor space pressure equalization line, and a liquidoutlet, wherein the vessel contains a pair of connected, horizontallyoriented, O-ring equipped sealing plates that are designed to rise andfall as a pair in response to gravity provided liquid pressure in thesump of the vessel, whereby an elevation of the sealing plates providesthe liquid in fluid communication with the liquid outlet. Embodiments ofa method of using embodiments of an apparatus of the present inventionare also provided.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present invention, reference isnow made to the accompanying drawings, in which:

FIG. 1 is cross-sectional side view of an embodiment of a flowcontrolling apparatus of the present invention in a sealedconfiguration.

FIG. 1A is a cross-sectional side view of an embodiment of a flowcontrolling apparatus of the present invention in a sealedconfiguration.

FIG. 2 is a cross-sectional side view of the embodiment of a flowcontrolling apparatus of the present invention depicted in FIG. 1 in anopen configuration.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION

The exemplary embodiments are best understood by referring to thedrawings, like numerals being used for like and corresponding parts ofthe various drawings. In the following description of embodiments,orientation indicators such as “top,” “bottom,” “up,” “down,” “upper,”“lower,” “front,” “back,” etc. are used for illustration purposes only;the invention, however, is not so limited, and other possibleorientations are contemplated.

Referring first to FIG. 1, in one embodiment a flow control apparatus100 comprises a vessel 2. In one embodiment, vessel 2 is a sealablecontainer adapted and configured to accommodate the liquid whose flowthere through is to be controlled. In one embodiment, vessel 2 comprises316L stainless steel, although the invention is not so limited andvessel 2 may comprise any useful material(s), such as, but not limitedto, other metals or metal alloys, plastic, polycarbonate, or graphite.In one embodiment (not shown), vessel 2 may be insulated, as would beunderstood by one skilled in the art. In one embodiment (not shown),vessel 2 may be equipped with a temperature control mechanism, such as,but not limited to, a steam jacket. In one aspect, such a temperaturecontrol mechanism may be positioned proximate at least a portion of theexterior of vessel and/or integral therewith. In one embodiment, atleast a portion of vessel 2 may be substantially tubular in shape.

In one embodiment, disposed within vessel 2 is a sealing component 4. Inone embodiment, sealing component 4 comprises an upper plate assembly 6,a lower plate assembly 8, and a substantially vertically oriented plateconnector rod 10. In one embodiment, plate connector rod 10 is attachedat an upper end 12 thereof to a bottom surface 14 of upper plateassembly 6 and/or plate connector rod 10 is attached at a lower end 16thereof to a top surface 18 of lower plate assembly 8. In anotherembodiment, upper end 12 of plate connector rod 10 may be integral toupper plate assembly 6 and/or lower end 16 of plate connector rod 10 maybe integral to lower plate assembly 8. In various embodiments, upperplate assembly 6 and/or lower plate assembly 8 may comprise a singlecomponent or a plurality of components, as would be understood by oneskilled in the art. In one embodiment, upper plate assembly 6 and/orlower plate assembly 8 may be substantially horizontally circular inshape. In one embodiment, a top surface 32 of upper plate assembly 6 isdome shaped, as depicted in FIG. 1.

In one embodiment, sealing component 4 is disposed substantiallyvertically within vessel 2. In one embodiment, a side surface 20 ofupper plate assembly 6 is disposed proximate a portion of the interiorwall 22 of vessel 2. In one embodiment, upper plate assembly 6 isequipped with one or more sealing members 24A. In one embodiment, atleast one of the sealing members 24A is disposed substantiallycircumferentially around a portion of upper plate assembly 6. In oneembodiment, side surface 20 of upper plate assembly 6 comprises one ormore grooves 26A into which at least a portion of a sealing member 24Amay be positioned. In one embodiment, sealing component 4 is positionedwithin vessel 2 such that at least a portion one or more sealing members24A abuts interior wall 22 of vessel 2, whereby upper plate assembly 6fluidly segregates an upper internal section 28 of vessel 2 from amiddle internal section 30 of vessel 2.

In one embodiment, a side surface 34 of lower plate assembly 8 isdisposed proximate a portion of the interior wall 22 of vessel 2. In oneembodiment, lower plate assembly 8 is equipped with one or more sealingmembers 24B. In one embodiment, at least one of the sealing members 24Bis disposed substantially circumferentially around a portion of lowerplate assembly 8. In one embodiment, side surface 34 of lower plateassembly 8 comprises one or more grooves 26B into which at least aportion of a sealing member 24B may be positioned. In one embodiment,sealing component 4 is positioned within vessel 2 such that at least aportion one or more sealing members 24B abuts interior wall 22 of vessel2, whereby lower plate assembly 8 fluidly segregates a lower internalsection (sump) 36 of vessel 2 from middle internal section 30 of vessel2.

In one embodiment, a sealing member 24A and/or 24B may be an O-ring. Aswould be understood by one skilled in the art, an O-ring 24A, 24B maycomprise any suitable material, such as but not limited to, anelastomer. In one embodiment, an elastomeric O-ring 24A and/or 24B maycomprise silicone. In other embodiments, an O-ring 24A, 24B may comprisea fluoroelastomer comprising tetrafluoroethylene and propylene (TFE/P),available from AGC Chemicals Americas, Inc. under the tradename AFLAS®,or a perfluoro-elastomer (perfluororubber), available from SealsEastern, Inc. under the tradename PERFLAS®.

In other embodiments, a sealing member 24A and/or 24B may be a pistonring. A piston ring 24A, 24B may comprise any suitable material. In oneembodiment, a piston ring 24A, 24B comprises metal and/or graphite. Inone embodiment, a piston ring 24A, 24B comprises cast iron or chromiumsteel. In one aspect, a piston ring 24A, 24B may be (or be similar to) astandard automotive compression piston ring, such as piston ringsavailable from Federal-Mogul Powertrain of Southfield, Mich. In variousembodiments, a piston ring 24A, 24B may comprise one or more coatingmaterials on at least a portion of the exterior surface thereof, or haveat least a portion of its exterior surface hardened, hardfaced,hardbanded, etc., as is known within the art.

In one embodiment, vessel 2 comprises one or more fluid conduits 38disposed at least partially within interior wall 22 thereof. In oneembodiment, a conduit 38 may be substantially annular in shape andhorizontally oriented. In one embodiment, a conduit 38 may extendcircumferentially about vessel 2. In one embodiment, vessel 2 comprisesa plurality of orifices (e.g., holes, slits, etc.) 40 which penetrateinterior wall 22 and provide for fluid communication between theinterior of vessel 2 and at least one conduit 38. In one aspect, atleast one fluid conduit 38 is in fluid communication with a fluid outlet42.

In other embodiments (not shown), vessel 2 may be provided wherein fluidoutlet 42 is in direct fluid communication with the interior thereof,i.e., wherein no orifices 40 and fluid conduits 38 are employed. In suchembodiments, liquid within sump 36 can flow directly into fluid outlet42 when flow control apparatus 100 is in an “open” configuration asdescribed below.

In one embodiment, flow control apparatus 100 comprises a liquid inletline 44 which is fluidly connected to sump 36. In one embodiment, liquidinlet line 44 comprises a substantially horizontal segment 54 and asubstantially vertical segment 46. As is described in detail below, theappropriate height and internal diameter of vertical segment 46 isdetermined by the density of the liquid (not shown) and the weight ofsealing component 4. In one embodiment, flow control apparatus 100comprises a vapor equalization line 48 which provides for pressureequalization between upper internal section 28 and liquid inlet line 44.

In one embodiment, sealing component 4 is adapted and configured to bevertically displaceable within vessel 2. In the embodiment shown in FIG.1, the sealing component 4 is in a vertical position wherein any liquid(not shown) in sump 36 is prevented by lower plate assembly 8 fromentering any orifices 40; i.e., flow control apparatus 100 is in a“closed” configuration with regard to liquid flow there through.

Referring now to FIG. 2, flow control apparatus 100 is depicted in an“open” configuration with regard to liquid flow there through. In oneaspect, when the weight of liquid (not shown) in sump 36 and verticalsegment 46 has forced lower plate assembly 8 (and therefore sealingcomponent 4) upward such that liquid (not shown) in sump 36 may enter atleast some of orifices 40, the liquid (not shown) flows into one or morefluid conduits 38 and out of flow control apparatus 100 via fluid outlet42.

In one embodiment, flow control apparatus 100 may be equipped with oneor more upper vertical stops 50, as shown in FIGS. 1 and 2. In theembodiment depicted in FIGS. 1 and 2, an upper vertical stop 50 may beaffixed to or integral with interior wall 22 of vessel 2, although theinvention is not so limited. In one embodiment, an upper vertical stop50 may extend circumferentially horizontally along interior wall 22,although other configurations may be employed. In one aspect, uppervertical stop(s) 50 is/are adapted and configured such that when sealingcomponent 4 (and therefore upper plate assembly 8) is displaced upward,the upper vertical stop(s) 50 prevent upward movement of sealingcomponent 4 beyond a certain height, as such upward movement is blockedby contact between top surface 32 of upper plate assembly and the uppervertical stop(s) 50.

In one embodiment, flow control apparatus 100 may be equipped with oneor more lower vertical stops 52, as shown in FIGS. 1 and 2. In theembodiment depicted in FIGS. 1 and 2, a lower vertical stop 52 may beaffixed to or integral with interior wall 22 of vessel 2. In oneembodiment, a lower vertical stop 52 may extend circumferentiallyhorizontally along interior wall 22, although other configurations maybe employed. In one aspect, lower vertical stop(s) 52 is/are adapted andconfigured such that when sealing component 4 (and therefore upper plateassembly 8) is displaced downward, the lower vertical stop(s) 52 preventdownward movement of sealing component 4 beyond a certain height, assuch downward movement is blocked by contact between bottom surface 14of upper plate assembly and the lower vertical stop(s) 52.

Operation

Generally, a flow control apparatus 100 is provided proximate a liquidsource (not shown) whose flow is to be controlled. The liquid (notshown), such as, but not limited to, molten sulfur, is allowed to flowinto horizontal segment 54 of liquid inlet line 44. In one aspect, itmay be preferable to maintain a vapor space above the liquid withinhorizontal segment 54. The liquid then flows downward through verticalsegment 46 of liquid inlet line 44 and into sump 36 of vessel 2. In oneembodiment, the flow control apparatus 100 is actuated when sump 36 isfull and a sufficient level (weight) of liquid has collected in verticalsegment 46. The appropriate internal dimensions of vertical segment 46are determined by taking into account the density of the liquid and theweight of sealing component 4 (along with frictional drag thereof alonginterior wall 22) such that when a desired amount of liquid is presentwithin vertical segment 46, the weight thereof forces liquid upwardagainst a bottom surface 72 of lower plate assembly 8, and forces lowerplate assembly 8, and therefore sealing component 4, upward sufficientlyto allow for the liquid to enter one or more of orifices 40, whichis/are no longer blocked by lower plate assembly 8. Liquid that entersan orifice 40 flows through a conduit 38 and out of flow controlapparatus 100 via liquid outlet 42. Thus, flow control apparatus 100allows for downstream flow of the liquid only when a desired quantitythereof has accumulated.

In one embodiment, as sealing component 4 rises and falls, vaporpressure in upper internal section 28 is equalized by vapor flow (ineither direction) through vapor equalization line 48. In one aspect, adomed configuration of top surface 32 of upper plate assembly 6 servesto minimize collection of any liquid (not shown) present in upperinternal section 28 by allowing for gravity drainage thereof back intoliquid inlet line via vapor equalization line 48. In one embodiment, tominimize collection of any liquid (not shown) present in upper internalsection 28, vapor equalization line 48 may be disposed verticallyproximate upper vertical stop 50, as depicted in FIGS. 1 and 2.

Referring now to FIG. 1A, an embodiment of a flow control apparatus 100comprising an embodiment of another vapor equalization system isdepicted. An embodiment of a vapor equalization system 56 is shown inFIG. 1A. In the embodiment of FIG. 1A, vapor equalization system 56comprises a vapor equalization chamber 58 in-line with vaporequalization line 48, although other configurations may be employed. Inone embodiment, vapor equalization system 56 comprises, within vaporequalization chamber 58, a flotation member 60, a flotation member seat62, and a flotation member stop 64.

In one embodiment, flotation member 60 comprises a substantiallyspherical component, although the invention is not so limited and othershapes are contemplated. In one embodiment, flotation member seat 62,which may be attached to or integral with the interior wall 68 of vaporequalization chamber 58, comprises a substantially annular componentthat extends horizontally at least partially circumferentially about theinterior of vapor equalization chamber 58. In one embodiment, flotationmember seat 62 comprises a single component, although the invention isnot so limited and other configurations may be employed. In oneembodiment, flotation member seat 62 comprises one or more openings 66extending vertically there through. In one embodiment, a flotationmember stop 64 comprises a substantially annular component thatprotrudes from interior wall 68 of vapor equalization chamber 58 andextends horizontally circumferentially about the interior of vaporequalization chamber 58. In one embodiment, a flotation member stop 64comprises a beveled bottom surface 70.

In one embodiment, when vapor equalization chamber 58 is substantiallydevoid of liquid, flotation member 60, which has an external diametergreater than the internal annular diameter of flotation member seat 62,rests on flotation member seat 62. In such a situation, vapor pressureequilibrates between upper internal section 28 and liquid inlet line 44by means of vapor equalization line 48 and vapor flow through vaporequalization chamber 58 via one or more of the openings 66, as would beunderstood by one skilled in the art. In one embodiment, when liquid(not shown) is introduced to vapor equalization chamber 58 (due to,e.g., a pressure surge in liquid inlet line 44), liquid may forceflotation member 60 upward into at least partial abutment with flotationmember stop 64, which has an the internal annular diameter less than theexternal diameter of flotation member 60. In such a situation, flotationmember 60, in conjunction with flotation member stop 64, substantiallyprevents liquid within vapor equalization chamber 58 from flowing intoupper internal section 28. In one aspect, such sealing of vaporequalization chamber 58 (from flotation member stop 64 downward) furtherinduces the pressurized liquid to flow through vertical segment 46,where increased pressure triggers actuation of flow control apparatus100 and the liquid is able to exit the system via fluid outlet 42, aspreviously described.

In other embodiments (not shown), flow control apparatus 100 may beequipped with other known pressure relief devices and systems, such as,but not limited to, devices and systems fluidly connected to upperinternal section 28.

Method

An exemplary method of flow control utilizing an embodiment of a flowcontrol apparatus 100 of the present invention comprises:

A Flow Control Apparatus Provision Step, comprising providing a flowcontrol apparatus 100 in fluid communication with a liquid source,whereby liquid is able to be introduced to the flow control apparatusvia a liquid inlet line, such as liquid inlet line 44;

A Liquid Introduction Step, comprising flowing liquid through the liquidinlet line and into a sump, such as sump 36; and

A Flow Control Apparatus Actuation Step, comprising flowing sufficientliquid into the flow control apparatus such that a volume of the liquidaccumulates in a vertical segment of the liquid inlet line, such asvertical segment 46, such that a sealing component, such as sealingcomponent 44, is vertically displaced, whereby a portion of the liquidis provided to orifices, such as orifices 40, and liquid flows, via oneor more fluid conduits, such as fluid conduits 38, out of the flowcontrol apparatus via a fluid outlet, such as fluid outlet 42.

The foregoing method is merely exemplary, and additional embodiments ofa method of utilizing a flow control apparatus of the present inventionconsistent with the teachings herein may be employed. In addition, inother embodiments, one or more of these steps may be performedconcurrently, combined, repeated, re-ordered, or deleted, and/oradditional steps may be added.

The foregoing description of the invention illustrates exemplaryembodiments thereof. Various changes may be made in the details of theillustrated construction and process within the scope of the appendedclaims by one skilled in the art without departing from the teachings ofthe invention. Disclosure of existing patents, publications, and/orknown art incorporated herein by reference is to the extent required toprovide details and understanding of the disclosure herein set forth.The present invention should only be limited by the claims and theirequivalents.

1. A flow control apparatus comprising: a vessel; a sealing componentcomprising: an upper plate assembly comprising one or more sealingmembers; a lower plate assembly comprising one or more sealing members;and a plate connector rod connecting said upper plate assembly to saidlower plate assembly; one or more fluid conduits; a vapor equalizationline; a liquid inlet line comprising a substantially vertical segment;and a liquid outlet; wherein: said sealing component is verticallydisplaceable within said vessel; said liquid inlet line substantiallyvertical segment is fluidly connected to a sump of said vessel; saidvessel comprises one or more orifices through an interior wall thereofwhich are each fluidly connected to at least one said fluid conduit; atleast one said fluid conduit is fluidly connected to said liquid outlet;an upper internal section of said vessel above said upper plate assemblyis in fluid communication with said liquid inlet line via said vaporequalization line; and when liquid in said substantially verticalsegment of said liquid inlet line provides sufficient force to a bottomsurface of said lower plate assembly and causes said sealing componentto be displaced sufficiently upward, liquid in said sump flows outthrough said liquid outlet via at least one of said orifices and one ofsaid fluid conduits.
 2. The flow control apparatus of claim 1, whereinat least one said fluid conduit is substantially annular in shape andhorizontally oriented.
 3. The flow control apparatus of claim 1, whereinat least one said sealing member is an O-ring.
 4. The flow controlapparatus of claim 1, wherein at least one said sealing member is apiston ring.
 5. The flow control apparatus of claim 1, wherein saidvessel is equipped with a stopping mechanism selected from the groupconsisting of: an upper stop that limits upward movement of said sealingcomponent; a lower stop that limits downward movement of said sealingcomponent; and both an upper stop that limits upward movement of saidsealing component and a lower stop that limits downward movement of saidsealing component.
 6. The flow control apparatus of claim 1, whereinsaid upper plate assembly comprises a dome-shaped upper exteriorsurface.
 7. A flow control apparatus comprising: a vessel; a sealingcomponent comprising: an upper plate assembly comprising one or moresealing members; a lower plate assembly comprising one or more sealingmembers; and a plate connector rod connecting said upper plate assemblyto said lower plate assembly; one or more fluid conduits; a vaporequalization system; a liquid inlet line comprising a substantiallyvertical segment; and a liquid outlet; wherein: said sealing componentis vertically displaceable within said vessel; said liquid inlet linesubstantially vertical segment is fluidly connected to a sump of saidvessel; said vessel comprises one or more orifices through an interiorwall thereof which are each fluidly connected to at least one said fluidconduit; at least one said fluid conduit is fluidly connected to saidliquid outlet; an upper internal section of said vessel above said upperplate assembly is in fluid communication with said liquid inlet line viasaid vapor equalization system; said vapor equalization system comprisesa flotation member; and when liquid in said substantially verticalsegment of said liquid inlet line provides sufficient force to a bottomsurface of said lower plate assembly and causes said sealing componentto be displaced sufficiently upward, liquid in said sump flows outthrough said liquid outlet via at least one of said orifices and one ofsaid fluid conduits.
 8. The flow control apparatus of claim 7, whereinsaid vapor equalization system comprises a flotation member seat.
 9. Theflow control apparatus of claim 7, wherein said vapor equalizationsystem comprises a flotation member stop.
 10. The flow control apparatusof claim 7, wherein said flotation member is substantially spherical.11. The flow control apparatus of claim 7, wherein said flotation memberis positioned within a vapor equalization chamber.
 12. The flow controlapparatus of claim 11, wherein said vapor equalization system comprises:a vapor equalization line fluidly connecting said vapor equalizationchamber to an upper internal section of said vessel; and a vaporequalization line fluidly connecting said vapor equalization chamber tosaid liquid inlet line.
 13. A method of utilizing a flow controlapparatus, comprising: providing the flow control apparatus of claim 1;and introducing a liquid to said sump via said liquid inlet line andsaid substantially vertical segment thereof, such that the weight ofliquid in said substantially vertical segment causes said liquid in saidsump to force said lower plate assembly, and therefore said sealingcomponent, sufficiently upward such that liquid flows out through saidliquid outlet via at least one of said orifices and one of said fluidconduits.
 14. The method of claim 13, wherein at least on said fluidconduit is substantially annular in shape and horizontally oriented. 15.The method of claim 13, wherein at least one said sealing member is anO-ring.
 16. The method of claim 13, wherein said vessel is equipped witha stopping mechanism selected from the group consisting of: an upperstop that limits upward movement of said sealing component; a lower stopthat limits downward movement of said sealing component; and both anupper stop that limits upward movement of said sealing component and alower stop that limits downward movement of said sealing component. 17.The method of claim 13, wherein said flow control apparatus comprises avapor equalization system comprising a flotation member.
 18. The methodof claim 17, wherein said vapor equalization system comprises aflotation member seat.
 19. The method of claim 17, wherein saidflotation member is substantially spherical.
 20. The method of claim 17,wherein said flotation member is positioned within a vapor equalizationchamber; and said vapor equalization system comprises: a vaporequalization line fluidly connecting said vapor equalization chamber toan upper internal section of said vessel; and a vapor equalization linefluidly connecting said vapor equalization chamber to said liquid inletline.